POTD- PROJECT OF THE DAY: What Did You Make In Your Shop Today?

brino said:
Goce
Is this the car that your infamous brother drives?
If so, could that be the cause? ;)
Brian
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Yeap, it's one of his cars. This one spends most of its driving in city traffic, heavy left foot and bad quality parts i'm suspecting. That disc is already at 8mm in less than 30k, i get 150-200k on my daily drivers on one clutch. But i don't keep my foot on the clutch at stop lights and i don't ride the clutch. And this is a big body car with 1,4L engine so it needs 2500rpm just to get going.
 
I miss Europe. In September, I bought the last Honda Fit to be made with a manual (2018) and it took a year to find, had to come across three states, and now nobody but my wife and I can drive it.

This is a typical response in America at the parts counter.

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When looking at my 'things to make' folder, I decided to think about what could be used most often to save work or to speed up or improve the projects that are done often. One thing that I have often wanted but so far done without is a chamfer machine for cleaning up corners of saw cut material. Having watched a few YT vids lately and thinking about the unused routers that are sitting in the wood shop, I decided that I would build a simple device for making nice, clean, safe corners on metal.

I chose the most useless router (an old Black and Decker 1-1/4 HP) to do some trial-and-error engineering. 1st thing was to make an angle shaped slide table and mill an opening for the endmill to stick through.

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Next, I quickly built a wooden version of the rest of the machine for testing.

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It actually worked pretty good except for the flexibility of the wooden bracket and the fact that the 1/4" router collet had seen better days. This router had been my Dads so was likely 40+ years old.

Day 2. It was time to choose a bigger router with a 1/2" collet. I had a 3 HP HF router that was attached to a jig that had been used in one of the operations of creating loose tenon M&T joints back in my days as a furniture builder. A steel frame that allowed for 2-way adjustment of the DOC was fabricated. That and the use of a solid carbide 1/2" end mill (Thank you Matt) resulted in a rigid and solid feeling machine. A router speed control was used to tame the 23,000 RPM motor.

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Next was to find a convenient place to put it. I wanted it to be handy to the band saw as that is mainly what it will be used to clean edges from. There is a heavy pedestal next to the saw that holds a bench grinder, belt/disk sander and a HF portaband saw. This was a perfect place for it and not in the way of other machines.

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All in all, I'm pleased with the way it came out and it will get much use.

Thanks for looking.
Aaron
 
Yesterday's hand labour made my back to hurt all day today, so after work i went shopping and bought me this transmission jack. Also an advert for an abandoned peugeot caught my eye, i don't know why but this car from the pictures begging to be saved, any thought should i buy, fix and dally drive this 406 wagon.
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I needed to cleanup my mill after doing some notching of tubing for my footbrake on the lathe. My ShopVac wouldn't start, plugged it in a different outlet and hit it a few times and it started. Then it wouldn't start again.
So broke it down, usually the switch goes on these. My other ShopVac the switch is by passed, and a wall switch is on the handle of the SS vac.
The switch was working, so I went to the motor and had to clean up the commutator. It was filthy. I had to do this on 2 other shop vacs.
I have never had to do anything on my Craftsman, or Rigid. My shop vacs all have issues. So did that..
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Then went on to welding the tubing to create a foot pedal. I'm not sure how, but I messed up the alignment of the footpedal part, I wanted it closer to the leg. I marked where the tubings should meet. And still I missed. GRRRRRR

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And finally I repaired a constant voltage, constant current (filtered, very smooth) OLD , ANALOG power supply. Glad I ordered the transistors, since they are showing up as discontinued on Mouser (but in stock) and DigiKey minimum is 100 pcs. It's back together and working. I wish I had a manual, since there are ports on the back and you can program this. It has some interesting components. When I bought this at a garage sale years ago, the guy was ****** (really P i s s e d is a violation ) that I didn't know what this was. It was the end of the sale and he was moving and no one wanted it, and I wanted it as a power supply. He told me it was more than a power supply, but he had no documentation.
edit: oh yea, I replaced the power cord, and so glad I did, there was no insulation on it where it made the turn to the connector block.. You couldn't see it under the other bundles of wire.
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And after welding the tubes today, I'm going to cut the cord on my grinders as well. First the cheap HF units, then the dewalt . I really like one cord over many. I had 3 plugged in and it was a mess. Just as easy to have one and just plug what I need right at the grinder. I think. We'll see.. the HF are cheap enough.
 
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